Powdered compact

Sintering invoives the densification and microstmcture deveiopment that transfonns the iooseiy bound particies in a powder compact into a dense, cohesive body [, 70, 71, 72 and 73]. The end-... 

Fig. 3.4 Compaction of alumina powder. Isotherms of nitrogen at 77 K, on (A) the uncompacted powder, and (B) on the powder compacted at a pressure of 1480 GN (96 ton in" ). Open symbols, adsorption solid symbols, desorption.

Fig. 3.20 Pore size distributions (calculated by the Roberts method) for silica powder compacted at (A) Ibtonin" (B) 64tonin (C) 130 ton in". The distributions in (a) were calculated from the desorption brunch of the isotherms of nitrogen, and in (h) from the adsorption branch.

Fig. 3.26 Comparison plots for compacts of silica and magnesia. In each case the adsorption of nitrogen at 78 K on the compact is plotted against that on the uncompacted powder, (a) and (b), comparison plot and adsorption isotherm for silica powder compacted at 130 ton in (c) and (d), comparison plot and adsorption isotherm for precipitated magnesia compacted at 10 ton in. Note that the upward sweep of the comparison plot commences at a relative pressure below the inception of the loop.

Diffusion is based mainly on the diffusion of vacancies grain boundaries may act as sinks for these vacancies. This vacancy movement and annihilation cause the porosity of the powder compact to decrease during sintering. 

Liquid-Ph se Sintering. Sintering ia the Hquid state refers to the sintering of a powder mixture of two or more components, of which at least one has a melting temperature lower than the others. The sintering temperature is then selected ia such a manner that a Hquid phase is formed ia which the soHd powder particles of the other components rearrange. A high density powder compact is the result. 

Safety ia the P/M industry workplace is also a concern regarding the operation of compacting presses. Guarding devices are required by OSHA to prevent injuries. Those devices applying specifically to metal powder compacting presses are described in a standard issued by the Metal Powder Industries Federation. 

Both zirconium hydride and zirconium metal powders compact to fairly high densities at conventional pressures. During sintering the zirconium hydride decomposes and at the temperature of decomposition, zirconium particles start to bond. Sintered zirconium is ductile and can be worked without difficulty. Pure zirconium is seldom used in reactor engineering, but the powder is used in conjunction with uranium powder to form uranium—zirconium aUoys by soHd-state diffusion. These aUoys are important in reactor design because they change less under irradiation and are more resistant to corrosion. 

The high elastic modulus, compressive strength, and wear resistance of cemented carbides make them ideal candidates for use in boring bars, long shafts, and plungers, where reduction in deflection, chatter, and vibration are concerns. Metal, ceramic, and carbide powder-compacting dies and punches are generahy made of 6 wt % and 11 wt % Co ahoys, respectively. Another apphcation area for carbides is the synthetic diamond industry where carbides are used for dies and pistons (see Carbon). 

Particle shape also affects the sintering of a powder compact. Jagged or irregular shaped particles, which have a high surface area to volume ratio, have a higher driving force for densification and sinter faster than equiaxed particles. High aspect ratio platey particles, whiskers, and fibers, which pack poorly, sinter poorly. 

Conventional Sintering. Ceramic sintering is usually accompHshed by heating a powder compact to ca two-thirds of its melting temperature at ambient pressure and hoi ding for a given time. Densification can occur by soHd-state, Hquid-phase, or viscous sintering mechanisms. 

Methods of Measurement Methods of characterizing the rate process of wetting include four approaches as illustrated in Table 20-37. The first considers the ability of a drop to spread across the powder. This approach involves the measurement of a contact angle of a drop on a powder compact. The contact angle is a measure of the affinity of the fluid for the solid as given by the Young-Dupre equation, or... 

The success of compression agglomeration depends on the effective utilization and transmission ofthe applied external force and on the ability of the material to form and maintain interparticle bonds during pressure compaction (or consolidation) and decompression. Both these aspects are controlled in turn by the geometiy of the confined space, the nature of the apphed loads and the physical properties of the particulate material and of the confining walls. (See the section on Powder Mechanics and Powder Compaction.)... 

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